Decking assembly and decking kit with hold-down clip

ABSTRACT

A decking assembly and decking kit with hold-down clip are disclosed. The decking assembly includes a supporting substructure, first and second lengthwise extending boards with lips extending outwardly and upwardly away from a side thereof and at least one hold-down clip having two downwardly extending tabs which engage the lips of adjacent boards to fix the boards to the substructure. The decking kit includes at least two such boards and at least one such clip, and may additionally include a fastener, such as a screw, and a screwdriver bit.

FIELD OF THE INVENTION

[0001] The present invention relates generally to decking assemblies andmore particularly to a decking assembly, and a decking kit including animproved hold-down clip.

BACKGROUND OF THE INVENTION

[0002] Decking assemblies typically include horizontal floors raisedabove the ground. Often such decking assemblies are attached adjacent toresidential and commercial buildings. Other uses for such deckingassemblies are boardwalks, boat docks, stairs, benches and bridges. Suchdecking assemblies are often formed from a substructure formed withjoists and headers. Several boards of lumber or other material are thentypically transversely fixed across the joists of the sub-frame, in agenerally parallel relationship, by way of nails driven through the topsurface of the boards.

[0003] These decking assemblies, while being adequate for most generalpurposes, exhibit several shortcomings. These include compromisedstructural integrity, difficulty in assembly, and limited aestheticappeal. The use of nails with wooden boards in conventional deckingassemblies exhibits each of these problems.

[0004] For example, with hammering it is easy to miss the head of thenail and cause unsightly dents and scratches on the top surface of theboards. Additionally, nails are prone to rusting, thus discoloring thetop surface of the boards and weakening the nail. This, in turn,compromises the structural integrity of the decking assembly. Also,nails have the tendency to cause wood to split, and to work up fromtheir placements when stressed, further compromising the structuralintegrity of the decking assembly. Moreover, it is difficult to achievea uniform spacing for each board.

[0005] Other shortcomings of known nail and wood decking assembliesinclude the vulnerability of wood to dramatic climate changes. Theconstant expansion and contraction of conventional wood and nail deckingassemblies often cause cracking and weakens the entire structure.Additionally, the appearance of nails from the top of the boards ofconventional decking assemblies results in an aesthetically displeasingappearance.

[0006] One alternative which results in a more visually pleasing deck isto counter-sink the nails and fill the hole with wood plugs. This,however, is expensive and time consuming. Often the plugs work out overtime, allowing water to collect and accelerating a rotting process.

[0007] Another alternative way of constructing decking assemblies whichhas been proposed includes the use of a nailing anchor to fix boards toa sub-structure from their bottom surface. Examples of such deckingassemblies are disclosed in U.S. Pat. No. 4,620,403 to Field; U.S Pat.No. 5,775,048 to Orchard; U.S. Pat. No. 4,965,980 to Leavens; and inCanadian Patent number 2,015,733 to Commins. While the use of a nailinganchor may address aesthetic concerns, such assemblies are typicallytime consuming to assemble. Moreover, they do not address any of themore important structural concerns arising from the use of nails in awooden structure.

[0008] Equally as significant, the use of nails or other fastenersdriven into wood boards makes disassembly and repairs of deckingassemblies difficult. Moreover, disassembled boards typically includenail markings and holes from previous assembly, and are not easilyre-used.

[0009] To avoid some of the shortcomings of wooden boards, the use ofpolymer boards has been proposed. Polymer boards do not rot or decaylike wooden boards. However, plastic and polymer boards are much moresusceptible to variations in temperatures and are also weakened by theintroduction of nails.

[0010] Additionally, clip-on boards have been proposed as an alternativeto nails. These are usually shaped in such a way as to dictate only onemanner of installation. This asymmetry causes problems with installationand maintenance. Additionally, clip-on boards are typically not secureand can be removed without any tools, making them both structurallyweaker.

[0011] Similarly, tongue and groove boards have been proposed to be usedin association with anchor clips which bend into place. However, thisoften results in a weaker structure with clips that are susceptible torust and loosening. Moreover, tongue and groove assemblies typically donot allow for drainage of water, that accompanies a typical freeze andthaw cycle.

[0012] Accordingly, an improved deck that addresses some of shortcomingof known decking assemblies is desirable.

SUMMARY OF THE INVENTION

[0013] An object of the present invention is to provide an improved deckthat is easy to construct, aesthetically pleasing and that may be lesssusceptible to rotting, splitting and decaying than conventional deckingassemblies, and that may be use in a variety of climate conditions.

[0014] A further object of the present invention is to provide adeck-kit that is conveniently packaged and that may be used to build animproved deck.

[0015] Therefore, in accordance with an aspect of the present invention,a decking assembly includes, a supporting substructure; a firstlengthwise extending board, having a lengthwise extending first lipextending outwardly and upwardly away from a side of the first board;and a second lengthwise extending board, having a lengthwise extendingfirst lip extending outwardly and upwardly away from a side of thesecond board. The first and second boards extend on the substructurewith the first lip of the first board and the first lip of the secondboard each extending upwardly and adjacent to each other. At least onehold down clip, is affixed to the supporting substructure, and includesa top portion; two downwardly extending tabs extending downwardlydefining a medial region between the downwardly extending tabs. Thedownwardly extending tabs press on the adjacent lips, thereby pullingthe first and second boards inwardly toward the medial region to securethe boards to the substructure.

[0016] In accordance with another aspect of the invention, a decking kitincludes at least two lengthwise extending boards, each including alengthwise extending lip extending outwardly and upwardly away from aside of the board; and at least one hold-down clip, to be affixed to asupporting substructure. The hold-down clip includes a top portion; twodownwardly extending tabs extending downwardly from the top portion,defining a medial portion therebetween. The tabs are for pressingdownwardly on adjacent lips of two boards placed on the substructure,thereby pulling the boards inwardly toward the medial portion to securethe first and second boards to the substructure.

[0017] In accordance with another aspect of the invention, a hold-downclip includes a top portion; and two downwardly extending tabs extendingdownwardly from the top portion, defining a medial portion therebetween.The tabs are adapted to press downwardly on adjacent lips of two boardsplaced on a substructure, thereby pulling the boards inwardly toward themedial portion to secure the boards to the substructure.

[0018] Other aspects and features of the present invention will becomeapparent to those of ordinary skill in the art upon review of thefollowing description of specific embodiments of the invention inconjunction with the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In figures which illustrate, by way of example only, embodimentsof the present invention,

[0020]FIG. 1 is a perspective view of a decking assembly, exemplary ofan embodiment of the present invention, with parts broken away showing asubstructure;

[0021]FIG. 2 is a perspective view of a first embodiment of a board thatmay be used to form the decking assembly of FIG. 1;

[0022]FIG. 3 is a perspective view of an alternative embodiment of aboard that may be used to form the decking assembly of FIG. 1;

[0023]FIG. 4A is a perspective view showing an example of a hold-downclip forming part of the decking assembly of FIG. 1, and exemplary of anembodiment of the present invention;

[0024]FIG. 4B is a cross-sectional view of the hold-down clip of FIG.4A;

[0025]FIG. 4C is a perspective view showing a further example of ahold-down clip that may be used to form part of the decking assembly ofFIG. 1;

[0026]FIG. 5 is a perspective view of a screw-driver bit that may beused to secure the hold-down clip of FIG. 4A to a joist of thesubstructure of FIG. 1;

[0027]FIG. 6A is a perspective view of two boards of FIG. 2 with ahold-down clip of FIG. 4A in place prior to being fixed to a joist; and

[0028]FIG. 6B is a perspective view of two boards of FIG. 2 with ahold-down clip of FIG. 4A in place after being fixed to a joist.

DETAILED DESCRIPTION

[0029]FIG. 1 illustrates a decking assembly 10, exemplary of anembodiment of the present invention. Decking assembly 10 may, forexample, be used as a residential patio deck, a boardwalk, a boat dock,stairs, a bench or a bridge. Other uses will be apparent to those ofordinary skill in the art.

[0030] Decking assembly 10 preferably includes a substructure 11including headers 12 placed around a plurality of joists 14 spacedevenly apart at a preferred distance of approximately one foot and in aparallel relationship to one another. Transversely placed upon thejoists 14 are a plurality of boards 16 spaced evenly apart in a parallelrelationship to one another and fixed together and to the substructure11 by way of hold down clips 24.

[0031]FIG. 2 illustrates an example board 16, used to form the deckingassembly 10, of FIG. 1. Board 16 is preferably not formed ofconventional wood, but is instead formed of composite wood by combiningwood particles with a resin and then extruding the mixture through anextrusion mold, resulting in a board 16 containing a multitude ofgenerally vertical ribs 20 extending lengthwise along each board 16between two flat surfaces 22 a and 22 b, and having a uniformcross-section throughout its length, as for example, detailed in U.S.Pat. No. 5,234,652, the contents of which are hereby incorporated byreference. Ribs 20 are preferably equally spaced apart and definerectangularly shaped chambers 21, extending parallel to one anotherbetween flat surfaces 22 a and 22 b along the length of board 16. Board16, when formed of composite wood, has the advantages of being resistantto termites, fungus, rot and decay, resistant to cracking orsplintering, is light weight, and reacts well to changes in temperature.As will be appreciated by those of ordinary skill in the art, board 16may also be formed of other materials such as conventional wood orplastic, and need not be made by an extrusion process.

[0032] Preferably, the dimensions of board 16 will be the same asconventional boards of lumber. Preferably, board 16 will be 2″×3″;2″×4″; 2″×6″; 2″×8″; 2″×10″; or 2″×12″ in height and width, and havelength which may vary depending on the size of the decking assembly.Additionally, the preferable number of ribs 20 per board 16 is five. Ofcourse, these specifications are merely examples of possible embodimentsand many variations of these are possible.

[0033] Extending from the sides of each board 16, proximate the edges ofeach flat surface 22 a and 22 b are lips 23 a and 23 b, respectively. Asillustrated, the top flat surface 22 a has downwardly angled lips 23 aextending from either side, and the bottom flat surface 22 b hasupwardly angled lips 23 b extending from either side. The lips 23 a and23 b preferably extend upward and downward at an angle of about 10° fromthe horizontal. Preferably, the angled lips 23 a and 23 b of the flatsurfaces 22 a and 22 b extend outward proximate an outermost rib 20 adistance of preferably approximately 0.8 cm. However, as a personskilled in art will appreciate, that such distance and angle may beincreased or decreased. Advantageously, as angled lips 23 a and 23 bextend from the left and right of top and bottom surfaces 22 a and 22 b,boards 16 are symmetrical about vertical and horizontal planes throughits center. Opposed angled lips 23 a and 23 b form generally dovetailedchannels 29, as illustrated. As will become apparent, lips 23 a and 23 bneed not extend outward linearly but could be curved or have anothershape.

[0034]FIG. 3 illustrates an alternate embodiment of a board 16′ suitablefor use as part of the decking assembly of FIG. 1. Board 16′ includescylindrical shaped chambers 21′, extending parallel to each otherbetween flat surfaces 22 a′ and 22 b′, along the length of the board andangled edges 23 a′ and 23 b′, otherwise possessing the characteristicsof the board 16 as in FIG. 2. The chambers 21′ are preferably evenlyspaced and of uniform diameter. The arcuate ribs 20′ provide additionalstrength to the board 16′. Board 16′ may be formed in the same way asboard 16, using a suitably shaped extrusion mold.

[0035]FIGS. 4A and 4B illustrate, in perspective and cross-sectionalview an exemplary hold-down clip 24. Hold-down clip 24 includes a topportion 25. Extending down from top portion 25 of hold-down clip 24 aretwo downwardly extending outer tabs 26 defining a medial region 27therebetween. Preferably, extending down, further than the outer tabs26, parallel to and equidistant to both outer tabs 26 in region 27 is aspacer tab 28. Thus, hold-down clip 24 is generally T-shaped incross-section, as best illustrated in FIG. 4B. Spacer tab 28 and eachouter tab 26 define a channel 34 a and 34 b in region 27 extending alongthe length of clip 24. Clip 24 is preferably made of plastic and may beformed by injection or extrusion molding. Of course, clip 24 could beformed of any other suitable material including a metal or alloy such asaluminum or steel.

[0036] Hold-down clip 24 optionally includes a bore 30, extending fromthe center of top portion 25. Bore 30 is sufficiently large to allow afastener, such as a nail or screw to pass from the center of the top ofclip 24 down through the center of the spacer tab 28. Two small soliddisks 32 formed as a result of the injection molding process formingspacer tab 28, protrude from the bottom of spacer tab 28, and arelocated on either side of the hole on the bottom surface of the spacertab 28.

[0037]FIG. 4C illustrates a perspective view of an alternative hold-downclip 24′ that may be used in place of hold-down clip 24 of FIGS. 4A and4B. Hold-down clip 24′ has a top portion 25′, downwardly extending tabs26′ extending down from top portion 25′ defining a medial region 27′,and preferably including a bore 30′ of sufficiently large diameter toallow a fastener, such as a nail or a screw to pass from the center oftop of hold-down clip 24′ down through the center of top portion 25′.

[0038]FIG. 5 illustrates a screwdriver bit 36 which has its operativeend extending a distance preferably at least the distance from the topouter edge of the angled edge 23 a of flat surface 22 a of board 16 tothe top inner edge of the angled edge 23 b of flat surface 22 b of board16, and most preferably a distance greater than the thickness of board16. As will become apparent, screwdriver bit 36 has a shaft that issufficiently thin to allow the adjustment of a screw positioned betweentwo boards 16 while permitting a minimum separation distance between theboards 16. Thus, preferably, the diameter of screwdriver bit 36 will beless than the thickness of spacer tab 28. Screwdriver bit 36 may be aRobertson, Philips, or slotted fit, complementary to screws that may beused to fasten the boards to the substructure 11.

[0039] The construction of a decking assembly as illustrated in FIG. 1using example hold down clip 24 and boards 16 may be better appreciatedwith reference to FIGS. 6A and 6B. Specifically, FIGS. 6A and 6Billustrate cross-sectional views of a hold-down clip 24 positionedbetween two boards 16. Boards 16 are placed in a side-by-siderelationship on substructure 11, with two lips 23 a of adjacent boardsadjacent to each other. As illustrated in FIG. 6A, hold-down clip 24 isplaced above one of joists 14 and between two boards 16 such that theangled lip 23 b of the bottom flat surface 22 b of one board 16 is fitwithin the first groove 34 a of hold-down clip 24. The angled lip 23 bof the bottom flat surface 22 b of another board 16 is fit within thesecond groove 34 b of hold-down clip 24. Hold-down clip 24 may befastened to substructure 11 using a conventional fastener such as anail, screw, staple or the like. Most preferably a screw, such as screw38 are used.

[0040] Screw 38 is positioned in the top hole 30 of hold-down clip 24and is turned by a screw driver, preferably fitted with screwdriver bit36 so that screw 38 is engaged by the complementary bit 36 and driventhrough the hold-down clip 24 and into the joist 14, causing a downwardforce to be exerted on hold-down clip 24. The downward force onhold-down clip 24 acting upon the angled edges 23 b of flat surfaces 22b causes a camming force to be exerted on each board 16 in a generallyhorizontal direction, orthogonal to the downward force, and towardshold-down clip 24 as illustrated by arrow P in FIG. 6B. This, in turn,pulls two adjacent boards close together. Conveniently, the diameter ofscrewdriver bit 36 is narrower than an extending center spacing tab andis sufficiently narrow to allow the screwdriver bit 36 to fit betweenadjacent boards as they are pulled together. Spacer tab 28 of thehold-down clip 24 conveniently limits the spacing between adjacentboards. Moreover, spacer tab 28 provides an upwardly directed supportingforce, opposite to the downward force of screw 38. As illustrated inFIG. 4C, spacer tab 28 could be eliminated thereby allowing a screw suchas screw 38 to act as a spacer between adjacent boards 16.

[0041] The combination of the camming force and the downward forcecauses a strong union between each board 16 and the sub-structure, aswell as between each board 16 and each adjacent board 16, resulting inan improved deck. Moreover, hold down clips 24 spaced along the lengthof the boards may cause adjacent boards to be equally and evenly spacedand parallel, eliminating the need measure or mark the position ofboards 16, as they are being assembled. Preferably, several clipsidentical to hold-down clips 24 are spaced lengthwise at one footintervals.

[0042] Advantageously, hold-down clips 24 need not be fixed from the topsurface of boards 16, nor through any surface of boards 16. Eachhold-down clip 24 is economical to produce, unobtrusive, and results inan aesthetically pleasing deck.

[0043] As boards 16 are symmetrical, downwardly extending lips 23 a willbe adjacent to each other. So arranged, these facilitate water run-offfrom an assembled decking assembly 10, and additionally prevent unevenboard edges that may cause tripping or interfere with snow removal.

[0044] As should now be appreciated, if a decking assembly so assembledneeds to be disassembled, fasteners may be removed from hold-down clips24. Boards 16 remain undamaged by any such disassembly. Moreover, as theboards are symmetrical, any board having a damaged or discolored facemay easily be reversed, by loosening the associated fasteners keepingthe board in place, and turning the board 180° and thus reversing theboard. Similarly, severely damaged boards may be replaced, one by one,as required. This, in turn, may significantly extend the useful life ofany such decking assembly.

[0045] Conveniently, boards 16, hold down clip 24, and optionalscrewdriver bit 38 may be packaged as a kit, packaged for distributionand sale. Such a kit may further include suitable instructions,fasteners, such as nails or screws that may be used to attach hold-downclip 24.

[0046] The above described embodiments, are intended to be illustrativeonly and in no way limiting. The described embodiments of carrying outthe invention, are susceptible to modification of form, size,arrangement of parts, and details of operation. The invention, rather,is intended to encompass all such modification within its scope, asdefined by the claims.

What is claimed is:
 1. A decking assembly comprising: a supportingsubstructure; a first lengthwise extending board, comprising alengthwise extending first lip extending outwardly and upwardly awayfrom a side of said first board; a second lengthwise extending board,comprising a lengthwise extending first lip extending outwardly andupwardly away from a side of said second board; said first board andsaid second board extending on said supporting substructure with saidfirst lip of said first board and said first lip of said second boardeach extending upwardly and adjacent to each other; at least one holddown clip, affixed to said supporting substructure, comprising a topportion; two downwardly extending tabs extending downwardly from saidtop portion defining a medial region between said downwardly extendingtabs, said downwardly extending tabs pressing on said adjacent first lipof said first board and first lip of said second board, thereby pullingsaid first and second boards inwardly toward said medial region tosecure said first and second boards to said substructure.
 2. The deckingassembly of claim 1, further comprising a spacer extending downward fromsaid center of said top portion, between said two downwardly extendingtabs, said spacer spacing said boards.
 3. The decking assembly of claim2, wherein said spacer comprises a downwardly extending spacer tab onsaid hold-down clip.
 4. The decking assembly of claim 2, wherein saidspacer comprises a screw extending through said hold-down clip.
 5. Thedecking assembly of claim 2, wherein each of said downwardly extendingtabs forms a channel with said spacer, and wherein an edge of one ofsaid first lip and said second lip is received in said channel.
 6. Thedecking assembly of claim 1, wherein each of said first and secondboards is formed of extruded composite wood.
 7. The decking assembly ofclaim 1, wherein each of said first and second boards each comprises aplurality of ribs extending lengthwise along a length of each of saidfirst and second boards, and vertically between a top and bottom of eachof said first and second boards.
 8. The decking assembly of claim 6,wherein said ribs are equally spaced apart.
 9. The decking assembly ofclaim 1, wherein each of said boards are formed with a plurality of ribsextending arcuately between two flat surfaces.
 10. The decking assemblyof claim 1, wherein said hold-down clip is formed from one of plastic,steel and aluminum.
 11. The decking assembly of claim 1, wherein saidhold-down clip is fastened to said substructure by a screw.
 12. Thedecking assembly of claim 1, wherein first board comprises a lengthwiseextending second lip extending outwardly from said side beside saidfirst lip.
 13. The decking assembly of claim 12, wherein said lengthwiseextending second lip extends downwardly, whereby said first and secondlips of said first board define a dovetailed groove between said firstand second lips of said first board.
 14. The decking assembly of claim13, wherein said second board comprises a lengthwise extending secondlip, extending outwardly and downwardly from said side beside said firstlip of said second board whereby said first and second lips of saidsecond board define a dovetailed groove between said first and secondlips of said second board.
 15. The decking assembly of claim 13, whereinsaid first board comprises: a third lengthwise extending lip extendingupwardly from a second side of said board; a fourth lengthwise extendinglip, extending downwardly beside said third lip on said second side saidfirst, second, third and fourth lips allowing said board to be reversedwith said fourth lip taking the place of said first lip, and the topsurface of said board taking the place of a bottom surface of saidboard.
 16. A decking kit comprising: at least two lengthwise extendingboards, each comprising a lengthwise extending lip extending outwardlyand upwardly away from a side of said board; at least one hold-downclip, to be affixed to a supporting substructure, said hold-down clipcomprising a top portion; two downwardly extending tabs extendingdownwardly from said top portion, defining a medial portiontherebetween, said tabs for pressing downwardly on adjacent lips of saidtwo boards placed on said substructure, thereby pulling said boardsinwardly toward said medial portion to secure said first and secondboards to said substructure.
 17. The decking kit of claim 16 whereinsaid boards are formed from extruded composite wood.
 18. The decking kitof claim 16, further comprising a screw to fasten said at least one clipto said substructure.
 19. The decking kit of claim 18, furthercomprising a screwdriver bit for fastening said screw.
 20. The deckingkit of claim 19, wherein said screwdriver bit is longer than a thicknessof at least one of said boards.
 21. The decking kit of claim 20, whereinsaid at least one clip comprises a downwardly extending spacer tab onsaid hold-down clip, to laterally space said two boards on saidsubstructure.
 22. The decking kit of claim 21, wherein said screwdriverbit has a diameter less than a thickness of said spacer tab.
 23. Ahold-down clip comprising: a top portion; two downwardly extending tabsextending downwardly from said top portion, defining a medial portiontherebetween, said tabs for pressing downwardly on adjacent lips of twoboards placed on a substructure, thereby pulling said boards inwardlytoward said medial portion to secure said first and second boards tosaid substructure.
 24. The hold-down clip of claim 23, furthercomprising a spacer tab extending downwardly between said two downwardlyextending tabs.